I've decided to try my hand at making a Magneto helmet for a Halloween costume I'm planning for this year. I'm going with the version from X-Men First Class at the end when he's all Mag'd out. Using a pepakura file and card stock. Will be resining and fiberglassing when done.

I've never really done it myself, but I've read up ALOT on it in the past few months. You coat the outside with resin, let it dry and then put fiberglass cloth and resin on the inside to reinforce it further. Then you use some sort of filler (like Bondo or something similar) on the outside to get it the right shape and get rid of the angles.

You can find tutorials on it on therpf.com, mercs.firespray.net or on Halo costuming forums. I think the Halo stuff is really what popularized the pepakura technique.

cut into the helmet a bit on the sides to correct the warping and secured it with this brace in the front. Also reinforced some of the corners with just a higher quantity of Elmer's to stiffen them more so they'll survive my move in a few days.